Micropellets of fine particle nutrients and methods of incorporating same into snack food products

ABSTRACT

Nutritious granular materials of fine particle sizes agglomerated within versatile micropellets are useful for inserting significant amounts of nutritious properties into snack foods. Expandable micropellet-containing formulations provide for introduction of fine particle ingredients such as proteins, minerals and other components or desirable nutrients into food processing lines not typically amenable to the fine particle sizes. Micropellet-containing formulations may consist entirely of micropellets, or may contain an expandable starch such as, for example, corn meal, sheeted doughs, and expanded collet products onto which the micropellets may be basted.

BACKGROUND

1. Technical Field

The present invention generally relates to methods of incorporatingingredients comprised of fine particles that are otherwise difficult towork with into a variety of snack food products. In particular, thepresent invention relates to micropellets comprising nutritious powdercomponents and the snack food products made therewith.

2. Description of Related Art

Grains such as corn are highly useful ingredients for the preparation ofready-to-eat snack food products. While these grains contain valuablenutrients, the incorporation of nutritionally advantageous materialand/or functional ingredients from other sources remains a topic of highinterest in the food industry. However, such inclusion is rarely an easytask. The problems that most food processing platforms experience lie,to some extent, with the high temperatures and/or high pressures used inthe production and processing of ready-to-eat snack food products. Suchconditions tend to substantially degrade any heat-labile ingredients tothe point of significant or complete loss of functionality. Cookingprocesses tend to change minerals, amino acids and vitamins intounusable forms, destroying and heat denaturing desirable nutrients ofmany heat-labile components. Thus, inclusion of amino acids, proteins,flavors, spices, vitamins, minerals and other heat-labile ingredients ingeneral tends to be problematic due to the loss of their structure witha correlating undesired loss of nutritional properties of theseingredients when subjected to high temperatures or pressures for cookingExacerbating the problem is the small granular or powder-like forms inwhich many of these ingredients are typically available. These formsoften prove difficult and, in some cases, even impossible to incorporateinto certain production lines.

Corn collets, for example, are popular consumer items produced andmarketed under the Cheetos® brand label, for which there exists a greatdemand. These products are generally made by extruding moistened cornmeal through an extruder, followed by a drying step such as baking orfrying to remove additional moisture after extrusion to produceshelf-stable, ready-to-eat snack products. Since the introduction ofextruders in the industry, many different varieties of these cornmealsnacks have been introduced. However, corn, or cornmeal, remains by farthe most common ingredient used for these direct-expanded snack foodproducts; not only due to the desirable expansion properties of corn,but also due to the equipment (or extruder) that dictates and oftenlimits the range of usable raw materials.

FIG. 1 depicts one well-liked variety of corn collets, known as randomcorn collets 2, having unique, twisted (“random”) shapes andprotrusions. These dense random corn collets 2 comprise a unique andhighly desirable crunchy texture that can only be produced viaspecialized extrusion processes, utilizing a rotating disk die extruder.It is a widely known and generally accepted fact in the industry thatrotating disk die extruders (also known as random extruders) cannothandle flour-like granular materials. Instead, random extruderformulations typically comprise only corn grits or corn meal to createthe collets 2 of FIG. 1. By way of example, Tables 1 and 2 provide,respectively, a typical corn meal particle size distribution for usewith a random extruder and a typical formula as introduced into a randomextruder.

TABLE 1 Corn meal Specifications US sieve size Typical analysis (%) on16 0 on 20 <1 on 25 9 on 30 43 on 40 45 on 50 2 through 50 <1

TABLE 2 Fried corn collet formula Ingredient Into Extruder (%) Corn meal96 Water 4

Introduction of anything other than refined farinaceous materials suchas corn meal (having bran and germ removed) into the random extruder hasproved extremely difficult. In particular, granular materials such asflour or powder typically cause blockage and halt production in randomextrusion lines. Very little, if anything, has been done in the industryto address the problems presented by the random extruder since itsintroduction in the 1940s. While it may be possible to incorporate someamounts of other ingredients to slightly modify the direct expandedproducts, to date, these amounts are not large enough to significantlyvary the nutritional properties of the random collet. Indeed, it seemssimply accepted that the random extruder has very narrow capabilities interms of formula or ingredient variations.

Consequently, it remains desirable to have a method for incorporatingflour-like ingredients in the random extruder. In particular, theintroduction of these ingredients into a random extruder while mimickingthe appealing characteristics of the crunchy corn collet 2 is highlydesirable; namely, taste, appearance and mouthfeel (or texture). Thereis further a need for methods of eliminating and overcoming the problemscaused by the narrow capabilities of the random extruder as well as hightemperature processes that degrade heat sensitive nutrients. Inaddition, it is desirable to have methods that allow for takingadvantage of the nutritional aspects of ingredients that may becomprised of fine or flour-like particles. Such methods should allow forthe inclusion of high amounts of these nutritional components other thangrains into snack foods, including, for instance, the highlysought-after, dense and crunchy random corn collets 2. It is alsodesired that the introduction of ingredients other than corn notinterfere with commercial production throughput levels, whileadvantageously affecting the nutritional aspects of the final snack foodproduct. Such snack food products should emulate the organolepticproperties, including taste and texture, of a conventionally producedshelf stable and ready to eat snack food product made of grains such ascorn.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa mode of use, further objectives and advantages thereof, will be bestunderstood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 depicts an illustration of typical random corn collets as knownin the industry.

FIG. 2 depicts a perspective view of a random extruder used inmanufacturing collets.

FIG. 3 depicts a close-up view of the main working components of therandom extruder depicted in FIG. 2.

FIG. 4 depicts a detailed cross-sectional view of the main workingcomponents shown in FIG. 3.

FIG. 5 depicts a close-up view of the area within the dashed lines ofFIG. 4.

FIG. 6 depicts a typical overall random extrusion line process.

FIG. 7 depicts one embodiment of the improvements to the randomextruder.

FIG. 8 depicts a plurality of random collets made according to a firstaspect.

FIG. 9 depicts a plurality of random collets made according to a secondaspect.

FIG. 10 depicts a plurality of random collets made according to a thirdaspect.

FIG. 11A depicts an expanded snack food with micropellets according afourth aspect.

FIG. 11B depicts a snack food in both pre-expanded and expanded statesaccording to another aspect.

FIG. 11C depicts a snack food in both pre-expanded and expanded statesaccording to another aspect.

FIG. 12A depicts a differential scanning calorimetry scan formicropellets in one embodiment.

FIG. 12B depicts a differential scanning calorimetry scan formicropellets made by way of marumerization.

FIG. 13A depicts a rapid visco analyzer pasting curve for themicropellets in one embodiment.

FIG. 13B depicts a replicate run of a rapid visco analyzer pasting curvefor the micropellets of FIG. 13A.

FIG. 14A depicts a rapid visco analyzer pasting curve for micropelletsmade by way of marumerization.

FIG. 14B depicts a replicate run of a rapid visco analyzer pasting curvefor micropellets of FIG. 14A.

FIG. 15A depicts a phase transition analyzer scan for the micropelletsin one embodiment.

FIG. 15B depicts a replicate run of a phase transition analyzer scan forthe micropellets of FIG. 15A.

FIG. 16A depicts a phase transition analyzer scan for micropellets madeby way of marumerization.

FIG. 16B depicts a replicate run of a phase transition analyzer scan formicropellets of FIG. 16A.

DETAILED DESCRIPTION

Applicant has overcome the obstacles of incorporating ingredientscomprising fine particle sizes into food products, providing for methodsof diversifying and expanding the number of ingredients introduced intosnack food products. Specifically, the method described herein helpsovercome the poor conveyance properties of the random extruder tosuccessfully include significant amounts of ingredients other than corn.To date, this has proven virtually impossible. However, uniquemicropellets containing desired nutritious components comprised of fineparticle size allows for the incorporation of diverse components intofood processing lines that have never before been amenable to variedingredients. By agglomerating or pelletizing fine particles intodiscrete particles that can be conveyed through a random extruder, awide variety of ingredients (including without limitation minerals,vitamins, proteins, fibers, whole grains, and flavors) can beincorporated into snack foods such as the random corn collet 2 allowingfor the modification of the nutritional content of the snack foods.

Generally, micropellet agglomerates, referred to as a “micropellets,”comprised of fine ingredients such as, for example, flours, powders, andany other fine materials comprising small particle sizes, are used tocreate a variety of snack foods. The micropellets may comprise anynumber of minerals, proteins, flavors, vitamins, tubers, grains or otherfood components, regardless of fine size, for use in the production ofsnack foods. In one embodiment, micropellets are comprised of a starchagglomerated together with a mineral. In another embodiment,micropellets comprise a starch agglomerated with a protein. In oneembodiment, a formulation of micropellets comprises starch and at leastone other nutritional flour. In some embodiments, the starch is derivedform a cereal grain such as corn. In some embodiments, the othernutritional flour comprises a non-starch component.

The micropellets are highly versatile and prove useful in a number ofmethods as described herein. Micropellet-containing formulations can beused in a variety of cooking processes. For example, the micropelletsare capable of maintaining their physical integrity when subjected tothe high shear region of the random extruder, where the starch matrix ofthe micropellet undergoes phase transition and plasticizes similar tothe traditional corn meal formulations used. Thus, in one embodiment,the micropellets may be used with random extrusion processes.

In some embodiments, a micropellet-containing formulation comprises astarch-based material with the micropellets. In one embodiment, thestarch-based material may comprise an unagglomerated granularstarch-comprising component such as one derived from corn and havingexpanding properties. Micropellets may be combined with corn meal, forexample, and cooked using a random extruder to create random collets. Inanother embodiment, the starch-based material comprises an expandedproduct such as direct-expanded collets, onto which the micropellets canbe basted prior to a cooking process such as frying or baking. Inanother embodiment, the micropellets may be incorporated into astarch-based dough, with subsequent cooking steps to create a snack foodproduct. Thus, the micropellets can be combined with a variety ofstarches in a number of processing lines.

In an alternate embodiment, a formulation comprising substantially 100%micropellets having an expandable property is incorporated into a randomextruder, without the need for combining the micropellets with anexpandable starch-based material. Resulting collets contain diverseingredients with varied nutritional aspects, as compared to thetraditional collets comprised of corn meal. Thus, the micropelletsdescribed herein provide for a wide array of snack food productscomprising varied nutritional content.

The micropellet-containing formulations described herein can beincorporated into processing lines that would otherwise completelydegrade, alter or affect certain nutritional components, processing runsand/or textural aspects of final products. Versatile micropelletscomprised of flour or powder-like particles may be introduced into avariety of ready-to-eat snack foods. In one aspect, the micropelletshelp expand upon the raw materials that may be introduced into a randomextruder. In another aspect, the micropellets may be used in subsequentprocessing steps in the random extrusion line (i.e., followingextrusion). In another aspect, the micropellets provide forincorporation of additional nutritional ingredients into dough productsprior to cooking processes.

Agglomeration transforms fine particles into larger particles by theintroduction of external forces, and is known to add value to manyprocesses in a number of industries involving the use of finely dividedsolid materials. For example, in the food industry, agglomerated flourshave been particularly useful in the production of foods known for theconvenience factor of instant preparation, wherein agglomerates areprepared so that they will instantly disburse or dissolve in liquids.However, to date, these technologies have yet to be successfullyintroduced into snack foods as described herein. In particular, theintroduction of agglomerated flours as disclosed herein, as well as thespecific formulations of the micropellets allow for incorporation into anumber of cooking methods or lines.

The terminology employed herein is used for the purpose of describingparticular embodiments and should not be considered limiting.

As used herein, the phrase “fine particle” or “fine” is used to refer topowders, flours, and any other similarly sized fine materials comprisingsmall particles having a particle size of less than about 300 microns.In one embodiment, the fine particles may comprise particle sizes ofabout 250 microns or less. In another embodiment, the powders comprisefine particles of about 200 microns or less prior to agglomeration intomicropellets. In some embodiments, the particle size is between about150 to about 250 microns in diameter (or less than 60 mesh). Suitablefine ingredients may comprise a number of nutritional properties and mayinclude without limitation proteins, fruits, berries, vegetables,minerals, calcium, herbs, vitamins, inulin, fibers, whole grains,starches, beans, fish, seafood, meats, peas, botanical proteins,flavors, probiotics, or any supplements thereof, whether natural orartificial, as well as any combination thereof. The fine particle sizemay be a result of any number of manufacturing methods including withoutlimitation grinding, crushing, milling, pounding, or pulverizingprocesses; or, alternatively, as a result of nature or natural causes.

As used herein, the term “agglomerate” relates to the product of somesize enlargement process such as one resulting in a substantially solidmicropellet as described herein. As used herein, the terms agglomerationand pelletization are used interchangeably.

As used herein, the term “micropellet” is meant to refer to asubstantially solid small pellet agglomerate comprising a spherical orcylindrical shape and a diameter no larger than about 1.8 mm (1800microns) with a plurality of agglomerated components of fine particlesize therein. The micropellets are capable of plasticizing into aviscoelastic dough and comprise an expanding property, which causes thegelatinization of the micropellets when subjected to heat or shortcooking processes such as random extrusion or baking, or a suddenpressure drop. The micropellets described herein have low waterabsorption index and can thus last for very long time when submerged inwater, absorbing very little moisture. Further details of theembodiments, formulations and manufacturing of the micropelletagglomerates presented herein are provided below and such details shouldbe understood to fall within these characteristics.

Micropellets

The micropellets will now be further described. It should be understoodthat these micropellets may be manufactured as described herein orobtained or purchased from any vendor capable of manufacturing same.

In general, the micropellets are comprised of agglomerated fineparticles. More particularly, the micropellets mimic the granularcharacteristics and/or size of corn meal or corn grits. In oneembodiment, a food-grade micropellet as described herein comprises anexpandable starch-comprising component; and a plurality of fineparticles agglomerated together with said expandable component, whereinsaid plurality of fine particles is derived from a non-starch source. Inone embodiment, the micropellets consist entirely of fine particlecomponents. Preferably, the micropellets comprise a starch-comprisingcomponent agglomerated with fine particles comprising a nutritiveproperty or nutrients unlike that of corn meal. In some embodiments, thestarch comprising components are present in varying concentrations offrom between about 20% to about 40%, with the remainder comprising anon-starch powder component. The ratio of fine particle to starch rangesfrom about 1.5 to about 4. In one embodiment, the fine particle tostarch ratio is about 60:40. In another embodiment, the fine particle tostarch ratio is about 70:30. In another embodiment, the fine particle tostarch ratio is about 80:20. In one embodiment, the fine particle tostarch ratio ranges from about 60:40 to about 80:20.

Suitable starch-comprising components for agglomeration within themicropellet include without limitation corn, rice, and potato orproducts derived therefrom. Preferably, the starch-comprising componentwithin the micropellet-containing formulation is one that gelatinizesupon cooking. Thus in one embodiment, the micropellets comprise astarch-comprising component selected from the group consisting of corn,rice, potato, a starch component derived from corn, rice, or potato, orany combination thereof. Such starch components may be modified ornative. In one embodiment, the starch-comprising component compriseswaxy corn starch. In one embodiment, the starch-comprising componentcomprises potato starch. In one embodiment, the starch-comprisingcomponent comprises corn meal. In one embodiment, the starch-comprisingcomponent is selected from the group consisting of the following: waxycorn starch, native corn starch, rice, tapioca, whole grain cereals,potato starch, or any combination or a starchy component thereof. In oneembodiment, the starch-comprising component comprises Maltodextrin. Inanother embodiment, the starch-comprising component may be derived fromthe starch components of whole grain corn. Such components are widelyavailable from any number of manufacturers.

Micropellet-containing formulations presented herein allow for therestriction and control of expansion in the production of snack foodproducts. For example, when subjected to random extrusion, a micropelletwill plasticize with the starch of a formulation introduced into theextruder. The micropellets will survive the shear in the randomextrusion process, but expand as they exit the extruder die. It shouldbe noted, however, that starches comprising low water binding capacitiesor low levels of amylopectin may not expand properly. For example, inembodiments comprising the introduction of fine particle proteins, thestarch matrix of the micropellet should comprise a minimum of about 25%amylopectin for proper expansion. In addition, waxy starches may be morepreferable than native starches, as waxy starches have been shown tohave better expansion properties during trial runs when combined withhigh amounts of protein (i.e. 80%).

In one embodiment, the fine particle components of the micropellet arenon-starch particles; meaning a substantial portion of the fineparticles is comprised of a nutritive component other than starch orcarbohydrates. Thus, in order to allow for varied nutritional content ina final food product, the fine particles comprise different nutritiveproperties or nutrients than those of the starch comprising componentsof the micropellet. For example, the fine particle components maycomprise a component not derived from corn, while the starch-comprisingcomponent is corn meal; or the fine particle components may comprise anon-carbohydrate powder or flour. In one embodiment, micropellets ofwhole grain cereals may also be produced, wherein the expandablestarch-comprising component comprises the starch of a seed and theplurality of fine particle components comprises the non-starchcomponents, or remaining parts, of the seed.

In one embodiment, the fine particle component of the micropelletcomprises protein. Any number of proteins may be incorporated, whetherin concentrate or isolate forms, including without limitation dairyproteins such as milk protein isolate, soy protein isolate, pea flourisolate, casein, soy protein concentrate, seaweed proteins,legume-derived proteins, egg protein, lentil protein, fish hydrolisidepowder, wheat protein, any protein derived from animal, vegetable ormarine source, protein derived from a plant seed such as a corn kernel,or any combination thereof. In one embodiment, the fine particles of themicropellets comprise between about 60% to about 80% protein.

While not all proteins may allow for continuous production ofmicropellets, it should be noted that batch portions of micropellets mayalso be manufactured. For example, in one embodiment, micropellets maycomprise a whey protein isolate (WPI). WPI is often difficult to workwith, as it typically produces a degree of stickiness that may hindercontinuous production. However, WPI portions may be substituted with upto 50% SPI if necessary.

In another embodiment, the fine particle component of the micropelletscomprises a mineral. In one embodiment, the fine particle componentcomprises calcium. Preferably, embodiments comprising an agglomeratedmineral include maltodextrin as a binder to group together the fineparticles. Micropellets comprising minerals may comprise, for example, amoisture content of about 8%. In one embodiment, the micropelletcomprises agglomerated calcium powder having particle size dimensionsclose to cornmeal. During test runs, micropellet products comprisingagglomerated calcium had a final moisture content of about 0.37% on awet-weight basis, after one or more drying steps. In one embodiment, thecalcium powder comprises from between about 35% to about 37.5% calcium.In one embodiment, the calcium powder comprises from between about 36.5%calcium, with the remaining balance being a starch around which thecalcium particles agglomerate.

During test runs, several formulations of micropellets were successfullytested in the production of snack foods, the methods for which arefurther discussed below. In one embodiment, the micropellets comprise acorn starch and a milk protein isolate. In one embodiment, the cornstarch is a waxy corn starch. In another embodiment, the corn starch isa native corn starch. In another embodiment, the micropellets comprise amilk protein isolate and a modified potato starch. In anotherembodiment, the micropellets comprise soy protein isolate with waxy cornstarch at a ratio of between about 60:40 and about 70:30. In oneembodiment, the micropellets comprise milk protein isolate with waxycorn starch at a ratio of between about 60:40 to about 70:30. In oneembodiment, the micropellets may comprise milk protein isolate andpotato starch at a ratio of between about 60:40 to about 70:30. Anotherembodiment of the micropellets may comprise about 60% starch or modifiedstarch from any grain source and about 40% whey protein isolation. Afurther embodiment of the micropellet formulation may comprise about 85%whole grain flour, about 15% of a high amylose starch, and about 5%fiber such as inulin. An additional embodiment of the micropelletformulation comprises 100% whole-grain cereals.

In additional embodiments, the micropellets may also comprisemicrocrystalline cellulose (MCC) as a processing aid to help manage themoisture properties of the micropellet. MCC is a physiologically inertsubstance derived from a naturally occurring polymer, which compactswell under minimum compression pressures and has high binding capacity.When used in tableting procedures, it creates tablets that are extremelyhard and stable, yet capable of disintegrating rapidly. MCC isparticularly valuable as a filler and binder for formulations preparedby direct compression, however it may also be used in wet or drygranulation and for spheronization or pelletization. During wetextrusion, MCC binds the moisture and therefore, the wetted mass becomesrigid to be extruded. At the same time in the spheronization process,the extrudates are still brittle enough to break into small cylindersand simultaneously plastic enough to convert into pellets. In someembodiments, the micropellets comprise up to about 10% MCC.

The micropellets described herein may be made by a variety ofagglomerations techniques so long as the process micropellets mimic theproperties of corn meal. Preferably, the micropellets should comprise ahigh degree of cook (substantially 100%) and form a compacted structure.A preferred method that may be used to manufacture the micropellets isextrusion, which basically requires extruding material through a cookingextruder to pre-cook the materials in forming a dough followed by aforming extruder with a die and then cutting the resulting strands toform pellets of uniform shape and size. Pre-cooking is performed usingeither a single or twin screw (cooking) extruding, followed by a formingextruder, which forms the dough into spaghetti-type strands using a diehead attached to a high rpm cutter. During some trial runs, micropelletswere pre-cooked in a single screw extruder run with a low shearconfiguration designed for pellet production. A suitable formingextruder, for example, is a G55 cooking extruder manufactured by Pavan.The components of the micropellet are placed either manually or with thehelp of unloading equipment into supply hoppers. A mixture of dry fineingredients and water-comprising liquids is premixed at high speed andis then cooked and extruded using an extrusion screw with modularsections and a jacketed cylinder with multiple cooking stages havingindependent temperatures. Comparable cooker extruders may also beemployed. By way of example, a suitable forming extruder for theproduction of micropellets from pregelatinized raw materials is a F55former-extruder known under the brand name Pavan. This extruder usesinterchangeable dies and a cutting group. Pre-cooked mixtures of ahomogenously hydrated and stabilized dough is formed using a compressionscrew, a cylinder with heating/cooling system, a headpiece and a die toform the product. Typically, a shaping die at the outlet of itsdownstream end, with a knife or knife cutting system located after thedie. Formed spaghetti-type strands are cut into micropellets, collectedvia hopper and dried overnight in forced air convection and cooled indryer temperatures of about 44° C. in a relative humidity of 66% forabout 480 minutes drying time. Preferably, when introducing heat-labilecomponents, low shear mixing occurs such that the mixing agitators andmixing speeds do not degrade or denature any proteins, flavors or othernutrients within the micropellet. These mixing components help toproduce a uniform blend of ingredients with a dough-like consistencythrough a distributive zone of the extruder. Liquid inlets of theextruder ensure proper conditioning or moisture addition into theformulation. Shaping takes place in the extruder as the material isextruded through holes in the shaping die. In one embodiment, the diehead comprises orifices of about 0.8 mm in diameter.

Wet extrusion and spheronization methods are also useful for formationof micropellets comprising heat-labile components because of the lowshear involved. Thus in one embodiment, the micropellets aremanufactured using the process of wet extrusion, followed byspheronization. As used herein, “spheronization” is used synonymouslywith the term “spheronizing,” and is meant to refer to the rounding ofmoist, soft cylindrical pellets in a spheronizer. While these processesare known in the field of pharmaceuticals, the formulations describedherein and the resulting micropellets are not. Briefly, the pre-mixeddry ingredients comprising a non-starch powder and a starch firstundergo a mixing step wherein they are moistened with water orwater-based solutions (such as a food grade solvent) and mixed in a highshear granulator or double planetary mixer to form a homogenous wet masssuitable for wet extrusion. Next, the wet mass is metered by a specialfeeder into a low shear extruder, such as a low shear dome or radialextruder, where it is continuously formed under into cylindricalextrudrates of uniform shape and size. The low shear ensures that theextruder temperature never reaches more than 80° F., protecting theheat-labile ingredients of the micropellets. Third, the wet extrudates,which comprise rod-like shapes are placed in a spheronizer where agridded, fast spinning disc breaks them into smaller particles androunds them over a period of about two minutes to form spheres. Fourthand finally, the wet spheres (also referred to as “beadlets”) are dried.This process can be performed as either a batch or continuous operationwith the above steps.

It should be noted that while in many cases it may be desirable tocreate micropellets capable of expansion, in some embodiments,micropellets having no expansion properties at all may be manufacturedfor inclusion into food products. For example, micropellets may becompletely comprised of cellulose, which does not expand but can beincluded in snack products. However, when utilizing fine particles withno expansion capabilities, it may be desirable to mix or dispersenon-expandable ingredients with at least 20% of a starch comprisingcomponent, or into a starch matrix, whether at least 20% starch isincluded within the micropellet or at least 20% starch is mixed with themicropellets prior to finish-product or food snack processing such aswith a random extrusion die.

In one embodiment, the bulk density of the resulting micropellets rangesfrom between about 500 to about 700 g/l. Without being constrained bytheory, it is believed that the particle size uniformity (size anddensity) of the micropellets ensure better mixing and less segregationin embodiments using a random extruder when compared to typicalformulations used comprising corn meal.

In general, the micropellets may comprise a number of shapes. In oneembodiment, the micropellets comprise a cylindrical shape. In anotherembodiment, the micropellets comprise a spherical shape. Micropelletsshould comprise a size of at least about 0.5 mm. In one embodiment,micropellets comprise a size of about 500 to about 700 microns (or about0.5 mm to about 0.7 mm). In some embodiments, the micropellets comprisea size of about 500 microns (0.5 mm). In one embodiment, the micropelletagglomerates comprise a short length with a diameter of about 0.8 mm. Inanother embodiment, the micropellet agglomerates comprise a longerlength of about 4 mm, with a diameter of about 0.8 mm. In oneembodiment, the micropellets comprise a diameter of between about 0.5 mmto about 1.0 mm. In another embodiment, the micropellets comprise adiameter of between about 0.5 to about 0.8 mm. In one embodiment, themicropellets comprise a particle size distribution wherein at least 75%of the agglomerates are larger than 50 mesh. More preferably, at least90% of the agglomerates are larger than 50 mesh. Most preferably, atleast 99.9% of the agglomerates are larger than 50 mesh. Micropelletscomprising smaller diameters are also possible in some embodiments;however, it may be preferable to pre-expand these prior to using themethods presented herein, as further discussed below.

Micropellet-Containing Formulations

The micropellets described herein are extremely versatile and allow forincorporation into a number of food processing methods or steps.Generally, a method of manufacturing snack food products comprises thesteps of providing an expandable micropellet-containing formulation,said formulation comprising a plurality of discrete micropellets havingfine particle components agglomerated therein; and cooking saidformulation to form a snack food product. The plurality of discretemicropellets comprises a particle size distribution wherein at least 75%of the micropellets are larger than 50 mesh. Further, the micropelletsare comprised of i) a starch-comprising component and ii) a plurality offine particles having nutritional properties unlike that of the starchcomprising food component.

In one embodiment, said expandable micropellet-containing formulationconsists only of said plurality of discrete micropellets. In suchembodiment, the method of manufacturing snack food products comprisesthe extruding of an expandable micropellet-containing formulationconsisting of a plurality of the discrete micropellets through a randomextruder.

In other embodiments, the expandable micropellet-containing formulationcomprises less than 100% micropellets. In such embodiments, themicropellet-containing formulation comprises a plurality of discretemicropellets and a starch-comprising food component. Such micropelletsmay or may not comprise an expandable property. Where the formulationcomprises less than 100% micropellets, the method of manufacturing snackfood products comprises the steps of: combining a plurality of discretemicropellets together with a starch-comprising food component to form amicropellet-starch mixture, wherein said micropellets are comprised ofi) a starch-comprising component and ii) a plurality of fine particleshaving nutritional properties unlike that of the starch comprising foodcomponent; and cooking the micropellet-starch mixture.

In one embodiment, micropellets are combined with unagglomeratedgranular starch comprising components and subsequently subjected to oneor more cooking processes; in particular, unagglomerated particlesderived from corn. In another embodiment, the micropellets are adheredor basted onto the surface of an unfinished food product (i.e., anintermediate food product no yet ready-to-yet) such as one that hasundergone only a first cooking step. In one embodiment, the unfinishedfood product comprises an expanded collet having exited an extruderincluding without limitation a random collet. The micropellets may bebasted or adhered onto the surface of expanded collet products andsubsequently subjected to final cooking to cause further dehydrationinto a shelf stable, ready-to-eat snack food. In another embodiment, themicropellets are embedded within sheeted doughs, which are thensubjected to cooking steps such as baking or frying.

When incorporated into formulations for direct expansion such as randomextrusion, as further discussed below, the micropellet-containingformulations are able to sufficiently expand when exposed to sufficientamounts of heat, whether or not the expansion is due to a starchcomprising component within the micropellet, or due to a starchcomprising component with which the micropellets are combined. Whenincorporated into a random extruder, the micropellets plasticize suchthat they substantially blend into the matrix of the collets resultingfrom direct expansion processes.

In embodiments wherein the micropellets are adhered to the surface ofsnack food products, the micropellets expand upon cooking. Themicropellets are capable of sufficient expansion even during shortcooking processes and as such, may be introduced into a number ofcooking lines in fairly high amounts that substantially improve upon thenutritional values of food snacks produced. Thus, in one embodiment, themicropellets may be incorporated into doughs during baking lines orprocesses. These methods are further discussed in detail below.

Random Extrusion

In order to better understand the limitations of the random extruder interms of its typical formulations, and the benefits of one embodiment ofthe present method, the inner workings of the random extruder are firstdescribed.

FIG. 2 illustrates a perspective view of a typical random extruder usedfor production of the random corn collets 2 depicted in FIG. 1. Itshould be noted that there are several manufacturers of the randomextruder; however the fundamental design is very similar. Randomextruders are high-shear, high-pressure machines, which generate heat inthe form of friction in a relatively short length of time. No barrelheating is applied in random extruders, as the energy used to cook theextrudate is generated from viscous dissipation of mechanical energy.

With reference to FIG. 2, pre-moistened cornmeal is gravity-fed througha hopper 4 and into the random extruder 6. In this manner, the extruder6 is choke-fed, taking in all it can take. The random extruder 6 iscomprised of two main working components: a single screw or auger 8 anda special die assembly (also known as a rotary die) 10 that gives thecollets their twisted (“random”) shapes. FIG. 3 illustrates a close up,more detailed image of the main working components 12 of the randomextruder 6. The auger 8 is housed in a cylindrical casing, or barrel 14,and comprises an open feed section 16 through which the cornmeal passes,shown in FIG. 3. The auger 8 then transports and compresses thecornmeal, feeding it to the die assembly 10. Once the auger 8 conveysthe material into the rotary die assembly, the working components grindand plasticize the formulation to a fluidized state in a glasstransition process.

As best shown in FIGS. 3-5, the die assembly 10 is comprised of a stator18 and a rotor 20. Gelatinization of moisturized starchy ingredientstakes place inside the concentric cavity between these two brass plates18, 20. The stator 18 is a round stationary brass plate that acts as adie through which the gelatinized melt flows. The stator 18 comprises astator base section 22 and a stator head 24 with grooves (not depicted)that aid in the compression of cornmeal as the stator 18 works togetherwith the rotor 20, which is a rotating plate comprising fingers (orblades) 26 and a nose cone 28. The nose cone 28 channels the cornmealtowards the fingers 26 and discharges the gelatinized cornmeal. Theaction of the fingers 26 creates the necessary condition of pressure andheat to achieve plasticization of the raw materials at approximately260° F. (127° C.). Specifically, the fingers 26 force cornmeal back intothe grooves (not shown) of the stator head 24, causing friction andcompression of the cornmeal. The brass facing on the rotor 20 also helpsto create heat and compression. Random extrusion may thus becharacterized by a thermo mechanical transformation of the raw materialsbrought about by the metal to metal interactions of the main workingcomponents 12 in a random extruder.

Several things happen within the die assembly 10 during the randomextrusion process. First, the corn meal is subjected to high shear ratesand pressure that generate most of the heat to cook the corn. Thus,unlike other extruders, most of the cooking takes place in the specialdie assembly 10 of the random extruder. Second, a rapid pressure losscauses the superheated water in the corn mass to turn to steam, puffingthe cooked corn. Third, the flow of corn between one rotating plate 20and one stationary plate 18 twists the expanding corn leaving it twistedand collapsed in places, resulting in the product characteristic shapeshown in FIG. 1. Cutter blades within a cutter assembly 30 then cut offthe collets 2 that result from the expansion process of the stator-rotorinteractions. The process is entirely unique, providing unsystematic,irregularly shaped collets and a texture distinct in its crunchiness.

As discussed above, it is known and accepted in the industry that randomextruders require uniform granulation to be able to generate the highfrictional energy necessary to produce the snack product and itsdesirable crunchy texture. Thus, to date, the inclusion of ingredientsother than refined cornmeal has proved extremely challenging, especiallyfor mass production processes. While other extruders may provide moreflexibility in terms of the components introduced therein, only randomextruders can create the random collet 2, which upon exit from therandom extruder, comprises a bulk density of ranging from between about3.0 to about 6.0 lbs/cu ft. or more preferably between about 4.0 toabout 5.50 lbs./cu ft. Twin screw extruders (TSE), for example, are lessdependent upon frictional properties as they provide for a positivedisplacement transport with the intermeshing of rotating twin screws.Thus, TSEs are more flexible due to their conveying mode and mixingcharacteristics. However, these extruders typically produce a differentvariety of collet; namely, corn puffs comprising a relatively smoothersurface and a more rod-like cylindrical shape with a lighter density. Byway of example, upon exiting from an extruder corn puffs produced from aTSE typically comprise a bulk density ranging from between about 1.8 toabout 2.8 lbs/cu ft, depending on size. Thus, while the TSE has betterconveying and pumping capabilities, and therefore greater flexibilityfor formula variation, TSE is still not capable of producing the denserrandom collet.

The conveyance through the auger is an important factor of the randomextrusion process. The method as described herein focuses upon andfacilitates this conveyance, while introducing different components thanever before successfully used. Specifically, by taking advantage ofagglomeration and/or pelletization technologies and methods, themicropellets are able to emulate the particle size of the corn mealtraditionally used in the random extruder to improve upon the conveyanceperformance through the auger of the random extruder when incorporatingother non-carbohydrate powders as a raw material. Thus, it has beenfound that uniformity of particle sizes provided by the micropelletswill facilitate conveyance through the auger and ensure good andcontinuous random extrusion. The plasticization of the micropellet andits formulation or blend also helps overcome the limited mixingproperties of the random extruder. In addition, certain improvements tothe metallurgy of the extruder itself provided also ensure continuousextrusion and proper expansion.

Micropellets within Random Collets

One embodiment for manufacturing snack food relates tomicropellet-containing formulations for the introduction into a randomextruder. As described above, applicants have found that by usingmicropellets capable of mimicking corn grits, random collets comprisinga nutritional content different from that of traditional collets may beproduced. Suitable micropellet-containing formulations properly expandand completely plasticize without leaving visible residue or remainingpieces of the micropellet in the final product. Consequently, in a firstaspect, the micropellets are introduced into and extruded using a randomextruder, which otherwise fails or locks up when fine particles,powdered or granular materials are introduced because the single augercannot generate a uniform flow.

FIG. 6 depicts a traditional random extrusion process for producingfried corn collets from start to finish and serves to illustrate oneembodiment, which will be further described in detail below. First,reference numeral I indicates one embodiment wherein the micropelletsmay be introduced into a random extruder. Second, reference numeral IIindicates another embodiment wherein the micropellets are introducedjust prior to the final cooking step of a collet. While FIG. 6 describesa process for producing fried random corn collets, it should be notedthat such illustration is not meant to limit the scope of thisembodiment. That is to say, micropellets may be used for the productionof a variety of snack foods, including fried or baked collets.

Briefly, as shown in FIG. 6, in a first step of a random extrusion line,a mixer 40 adds moisture as it mixes the raw materials. The mixer may bevertical, as depicted in FIG. 6, or horizontal (not pictured). The rawmaterials are then transferred to a bucket elevator 42, which elevatesthe materials to the extruder hopper of the random extruder (alsodepicted in FIG. 2). Next, extrusion 44 forms hard dense extrudedproduct utilizing rotating brass plates, as previously discussed abovewith reference to FIGS. 2-5. The product is then conveyed 46 to a finestumbler 48, which removes small fines from the product. The product thenpasses through a vibratory feeder 50 to provide even feed to a fryer 52,such as a rotary fryer, which decreases moisture and adds oil to theextruded product. Next, an additional vibratory feeder 54 transfersproduct to a coating tumbler 56, wherein oil, flavor and salt are mixed.The products can then be turned in a flavor drum 58, wherein flavor isapplied to the surface of the collets 2. This extrusion process isunique because each resulting collet 2, best shown in FIG. 1, issomewhat varied in length and diameter, giving somewhat of a home-madeeffect. Embodiments introducing a plurality of the micropellets will nowbe described.

In the formation of random collets, the method may comprise the stepsof: introducing into the random extruder an expandable mixturecomprising a plurality of micropellets, said micropellets having fineparticle components agglomerated therein; and extruding the mixture ofmicropellets through the random extruder. With reference to FIG. 6, themixture comprising a plurality of micropellets may be introduced atnumeral I.

In one embodiment, the micropellets comprise at least 60% of said fineparticle components. The fine particle components may comprise one ormore of the group consisting of protein, mineral, vitamin, fiber, fruit,vegetable, grain, meat, and any non-starch derivative. In oneembodiment, the fine particle components comprise a protein selectedfrom the group consisting of milk protein isolate, soy protein isolate,and whey protein isolate, or any combination thereof. In one embodiment,the fine particle components comprise a protein derived from the groupconsisting of animal, plant or marine source, or any combinationthereof. The micropellets may comprise a bulk density of between about500 g/L to about 700 g/L. In one embodiment, the micropellets compriseup to about 10% microcrystalline cellulose.

In one embodiment, the mixture comprising said plurality of micropelletsfurther comprises an expandable starch component. For example,micropellets and starch may be added, either consecutively orsimultaneously, directly into a blender at step 40 or through the feedsection 16 of a random extruder (shown in FIG. 3). As briefly describedabove, the micropellet-containing formulation may comprise astarch-comprising component combined with the micropellets. In oneembodiment, the starch-comprising component comprises unagglomerated,loose starch particles. Such unagglomerated, loose particles maycomprise corn meal. In another embodiment, the starch particles comprisecorn grits. Corn products suitable for use with the random extrusionprocesses are commercially available from any number of manufacturers,and would include, for example, any corn-derived product. In oneembodiment, the mixture may comprise an expandable starch componentselected from the group consisting of corn, potato, rice, and tapioca.

In one embodiment, the unagglomerated starch particles comprise aparticle size distribution wherein between about 30% to about 65% ofsaid particles fall between 500 to about 700 microns. In one embodiment,the unagglomerated starch particles comprise a particle sizedistribution wherein about 30% to about 50% of the particles are about500 microns. In another embodiment, the starch particles comprise aparticle size distribution wherein about 40% to about 65% of theparticles are about 500 microns.

The ratio of micropellets to starch-comprising component in themicropellet-containing mixture may vary, depending upon the amount ofstarch agglomerated within the micropellets and the desired level ofexpansion. In general, the higher the amount of starch in the overallmicropellet-starch mixture, the more expansion achieved. As statedabove, micropellet-containing formulations should comprise at least 20%of a high amylose starch. On the other hand, higher amounts of thenon-starch fine particle components provide for more significantvariations of the nutrients of the resulting collet. With sufficientamounts of starch within the micropellets, micropellet-containingformulations comprising substantially 100% micropellets, or consistingentirely of micropellets, may be cooked within a random extruder withoutthe starch-comprising component.

In one embodiment, a micropellet-starch mixture may comprise frombetween about 0.25% to about 2.5% of mineral micropellets, with theremaining balance of the mixture comprising unagglomerated starchparticles such as corn meal. In one embodiment, mineral micropelletsconstitute calcium micropellets comprising 90% calcium ingredient suchas calcium carbonate and 10% a binding or agglomerating component suchas starch. For example, during test runs, micropellet-containingformulations comprising approximately 2% agglomerated calcium andapproximately 98% yellow corn meal were successfully extruded usingrandom extruders. Despite the relative low quantities required informulations to achieve nutritional targets, the reactivity and fineparticle size of most minerals make their extrusion processingespecially difficult unless formulated into micropellets as disclosedherein.

In embodiments comprising protein micropellets, suitable formulations ofthe micropellet-containing formulation comprise at least 15% proteinmicropellets. In one embodiment, the micropellet-containing formulationcomprises at least 40% protein micropellets. In one embodiment, themicropellet-containing formulation comprises from between about 15%protein micropellets to about 41% protein micropellets. In oneembodiment, a protein micropellet-containing formulation comprises about20% protein micropellets comprising a milk protein isolate, with theremainder comprising a corn meal. In one embodiment a proteinmicropellet-containing formulation comprises between about 19% and about21% of a micropellet comprising a milk protein isolate.

In other embodiments, a combination of various micropellets may beincorporated into the micropellet-containing formulation or into amicropellet-starch mixture. For example, a micropellet-starch mixturemay comprise one or more of rice micropellets, porphyra micropellets,tapioca micropellets, milk protein isolate micropellets or soymicropellets.

The metallurgy of the random extruder is believed to influence expansionof the micropellets, in particular when using formulations comprisinghigh amounts of protein. With reference to FIGS. 3-5, in order to reducebiopolymer film formation on the rotor 20 observed in several randomextrusion runs using high protein micropellets, the bronze rotor plate20 was substituted with one made of stainless steel. Resultsdemonstrated substantial elimination of film formation with improvedprocess stability. Consequently, in one embodiment, extrusion isperformed using a rotor plate 20 comprised of stainless steel. Duringtest runs further described below, formulas containing milk proteinisolate were used to prove that the change in metallurgy had a positiveeffect on expansion and helped achieve continuous production of thenutritional collets, allowing for inclusions of high amounts of proteinmicropellets.

Returning to the discussion of FIG. 6, another reason for theinstabilities in the process when introducing non-traditional, non-cornformulations is the type of mixer 40 used to blend the corn meal withwater. The vertical mixer 40, which is typically used, requires longmixing times in order to raise the moisture up to about 16% or about17%. This process is very inefficient when using non-traditional cornmeal formulations with anything smaller in size, such as flours. Fineparticles or powders have a greater surface than the corn meal. As such,when introducing these smaller components, the more hygroscopic finescompete with the corn meal for water. Essentially, when water is appliedin the vertical mixer, the finer particles pick up moisture faster thanthose of the larger (corn meal) particles. When too much powder ispresent, the fines pick up the moisture faster than the rest of the mix,the corn meal. The finer powders or flours not only pick up the moisturefaster, but also form clumps that become a source of instability in theextruder because of the moisture disparity between the corn meal andflour. These clumps build up a mud-like film on the rotor and stator,which acts as lubricant in the special die assembly of the randomextruder and causes the extruder to choke, interrupting production.Thus, surface moistures are believed to contribute to random extruderlockup, halting production when a film is formed on the face of therotor 32.

Even when using the micropellets, in some embodiments comprising highamounts of proteins, for example, surface moisture should be avoided inorder to ensure continuous, uninterrupted production. Consequently, inone embodiment, the method further comprises pre-hydrating the pluralityof micropellets and the starch-comprising component. In one embodiment,the method comprises the step of separately pre-hydrating said pluralityof discrete micropellets prior to providing said micropellet-containingformulation. In one embodiment, the micropellets are pre-hydrated priorto combination with a starch-based component to a moisture level ofabout 16.5%. A pre-hydrating step may take place prior to the combiningof the micropellets and unagglomerated starch comprising particles(i.e., prior to the step of providing of said micropellet-containingformulation) such that said micropellet and starch components arepre-hydrated as separated entities. The starch-based food product to becombined with the micropellets thus comprises hydrated corn meal. In oneembodiment, corn meal is pre-hydrated to a moisture content of betweenabout 18% to about 25% when used as a premix with micropellets ofproteins, fibers, fruits and/or veggies. In one embodiment, themicropellets are pre-hydrated, separately from the corn meal, to amoisture content of between about 7% to about 15%. In one embodiment,the micropellets are pre-hydrated and allowed to equilibrate for atleast 6 hours prior to combination with the corn meal. In anotherembodiment, micropellets at their shelf-stable moisture content areblended with the rest of the formulation only after all necessary liquidto achieve target 16-17% moisture content of the formulation has beenseparately added to the corn meal or similar starch-comprising componentof the formulation. The final blend is allowed to equilibrate for about3 to about 6 hours. Pre-hydration can also be done by any means thatallows for moisture intake into the components, including withoutlimitation a steam chamber with mixing action as a pre-conditioner,water or water-based solutions, heated water in a mixer, and underpressure. In one embodiment, the micropellets and corn meal may bepre-hydrated together in a tempering process comprising the steps ofmixing and water application. In one embodiment, themicropellet-containing formulation comprises between about 15% to about70% hydrated corn meal. In one embodiment, the micropellet-containingformulation comprises between about 30% to about 75% hydratedmicropellets.

Alternatively, the method may further comprise the step of combining themicropellets and starch comprising component in a pre-hydrating step,wherein the micropellets and starch are combined and pre-hydratedtogether for a sufficient time to allow for moisture equilibration in atempering process prior to their introduction into the random extruder.Generally, the two should be prehydrated for a minimum of three hours toreach equilibrium. In some embodiments, pre-hydration steps may bepreferable when using embodiments wherein the micropellets compriseprotein in order to achieve desirable levels of expansion. When usingmineral micropellets, because of their relative lower proportion to thetotal formulation, pre-hydration can be accomplished by pre-blending themineral micropellet with the rest of the formulation for between about 5to about 10 minutes, and adding water or other food liquids whileblending for additional approximate 5 to 10 minutes to achieve 16-17%moisture content.

In order to ensure desirable expansion of the micropellet-containingformulation, the moisture content within the random extruder should beadjusted. Preferably, the moisture content within the random extrudershould not exceed 17% in order to achieve favorable expansion of thenutritional collets. In one embodiment, the micropellet-starch mixturesis extruded at a moisture content of between about 15% to about 17%within the random extruder. During some test runs incorporating proteinmicropellets, it was observed that residues of unexpanded, partiallyplasticized micropellets or blister-like inclusions in the collet matrixappeared when neglecting moisture content. This is believed to indicatethat expansion started but stopped most likely due to lack of enoughmoisture, or problems with the total moisture content necessary toachieve expansion. Well-expanded random collets should show micropelletexpansion and a fairly consistent cell structure, similar to those ofthe traditional random collets with no “crater-like” inclusions whereunexpanded micropellets may be embedded.

In an alternate embodiment to prevent film formation and ensurecontinuous production of random collets, the micropellets may bepre-cooked. Without being bound by theory, it is believed thatpre-cooking helps to prevent any slippage or lubricant-like effects onthe rotor or stator (i.e., loss of friction in the die assembly) byincreasing the resistance of the micropellets in the mixture to theshear forces in the stator. In addition, in embodiments using smallermicropellets, pre-cooking may result in desirable puffing or expansionto more desirable, larger sizes. Pre-cooking steps may comprise, forexample, roasting, baking and/or microwaving the micropellets prior totheir combining with the starch component for extrusion. Micropelletsmay be pre-cooked or pre-expanded to achieve a moisture content of about8-10% below the original moisture content of 11% to reduce plasticity.Preferably, the reduction of moisture is performed using lowtemperatures in overnight processes. For example, micropellets may bebaked/roasted/microwaved at temperatures of about between about 70° toabout 90° C. for about 12 hours. In one embodiment, expandablemicropellets comprising a particle size of less than about 0.8 mm indiameter undergo a puffing step prior to the step of combining with astarch for extrusion. In another embodiment, protein micropellets to bepre-cooked have a particle diameter less than between about 0.3 mm toabout 0.8 mm. Pre-cooking micropellets of this smaller size allows fortheir expansion into puffed micropellets having a larger particle sizesimilar to that of the unagglomerated starch particles with which themicropellets are combined prior to extrusion. Alternatively,micropellets comprising a particle size of about 0.8 mm may be roastedwith minimal expansion to attain a moisture content of about 8% to about10%.

In a further embodiment, the components within the micropellet may alsobe pre-cooked so as to reduce water or binding affinities. Thepre-cooking process may involve any process by which a powder or starchcomponent is subjected to alter its physicochemical properties includingwithout limitation fluidized bed and high temperature-short timeextruders such as, for example, cooking and forming extruders, or highshear extruders. Altered powder or starch components are thereafteragglomerated using any method known in the art.

In further reducing any process instabilities stemming from difficult,less traditional formulations for random extrusion, Applicants havefurther found that colder temperature may contribute to improvedcoefficients of friction in the rotor, reducing slippage and improvingthe drag flow of biopolymers. Accordingly, the random extruder may befitted with a temperature control device to help reduce processinstability when handling micropellets comprising heat-sensitivematerials such as proteins and fibers. Preferably, the work zone of arandom extruder comprises a cooling device to cool the work zone. In oneembodiment, the rotor of the random extruder comprises a cooling deviceor a cooling system. In another embodiment, the stator comprises acooling system. In another embodiment, depicted in FIG. 7, a randomextruder comprises a cooling system 38 adjacent or attached to both thestator head 24 as well as the rotor plate 20. The cooling system maycomprise any device or means of cooling the work zone including withoutlimitation a chill water jacket housing or water stream. One skilled inthe art should recognize methods of incorporating such a cooling system.For example, a recirculation of chill water in a honeycomb area of thelast section of the random extruder, in the stator zone, or downstreamof the stator, could be created. In one embodiment, the cooling systemcirculates a water bath to help dissipate the thermal heat generated bythe frictional impact of the extrusion process. To improve thecoefficient of friction and drag flow, the temperature of the dieassembly should comprise a range of between about 260° F. to about 275°F. Such lower temperatures (as compared to typical random extrusionprocesses with a range of between about 290° F. and about 300° F.)reduce slippage, resulting in a self-cleaning-type process duringextrusion. In addition, the lower temperatures achieve steady stateconditions necessary for continuous production and better productuniformity and flexibility.

FIG. 8 depicts random collets 60 a produced with micropellets comprisedof soy protein isolate and waxy corn starch and seasoned using cheddarseasonings. The micropellets used comprised a maximum size of about 0.8mm. The collets 60 a comprise about 5 grams of protein per one ounceserving, with unique and random shapes. While it is difficult to depictin illustrating the resulting collets, the resulting collet matrixshowed that the micropellets totally melted into the matrix. Inaddition, the flavor of the soy protein isolate and waxystarch-micropellet mix was not perceived in the cooked base.

Similarly, FIG. 9 depicts random collets 60 b and 60 c produced withmicropellets comprising milk protein isolate and waxy corn starch.Collets 60 b comprise 5 grams of protein and collets 60 c comprise 10grams of protein. Both comprise the unique random shapes substantiallysimilar to those collets 2 of traditional corn meal formulations asshown in FIG. 1. It should be noted that these collets as depicted inFIG. 9 have been cooked via expansion in the extruder, but have not yetundergone cooking or optional seasoning steps.

Micropellets Adhered onto Collets

In another embodiment, a plurality of micropellets can be combinedtogether with a starch-comprising component to form amicropellet-containing formulation, wherein the starch-comprisingcomponent is an expanded collet, and thereafter subjecting themicropellet-containing formulation to a final cooking step. As describedabove with reference back to FIG. 6, reference numeral II provides oneexample at which micropellets might be combined in accordance with oneembodiment. Said combining comprises an adhering or basting step,wherein the micropellets are basted onto the surface of expandedcollets. Preferably, a biopolymer such as starch or protein can be usedas a base emulsion externally or basted onto the surface of the collets.For example, during trial runs, 3% by weight of carboxymethyl cellulosewas basted onto random collets using a spray bottle. In one embodiment,one or more starch media binders may be used for topical application orcoating onto the collets prior to combining with micropellets. Suitablebinders include for example corn modified starch manufactured by NTAC™,surface binders such as carboxymethyl cellulose, fiber binders, starchbinders, protein binders, gels, sugars, combinations of sugars andwater, gums or any food grade binder, or any combination thereof. Starchbinders may further comprise protein powder, fiber, powdered nuts, orany combination thereof. Starch binders are preferred in embodimentswherein it is desired to add a secondary textural experience, or doublecrunch.

After the basting process, collets can be sprinkled with micropellets,which adhere to the surface of the basted collets. In one embodiment,the collets are sprinkled with pre-cooked or pre-puffed micropellets.Micropellets may be pre-puffed in some embodiments using for example airpuffing, microwaving or baking to heat the micropellets to a temperatureof about 350° F. Immediately after the combining of the micropellets tothe surface of basted collets II, with reference to FIG. 6, the bastedcollets are subjected to a heating process wherein the binder matrix isset, tightly binding the micropellets. In FIG. 6, such heating processdepicted is a frying step 52. However, such heating process may alsoinclude for example baking or other cooking processes that cause themicropellets to expand and/or set.

FIG. 10 depicts an illustration of collets 62 resulting from bastingprocesses as described herein, having micropellets 64 basted thereon.Any of the expandable micropellets as described above may be basted ontoan expanded collet 62 to vary the nutritional content of a collet. Inone embodiment, the micropellets are basted or adhered onto atraditional random collet 2, such as those depicted and described withreference to FIG. 1. In another embodiment, the micropellets are bastedor adhered onto the surface of nutritional random collets asmanufactured in the first embodiment described above (shown for examplein FIGS. 9 and 10), wherein micropellets have been included within thematrix of the collets. Thus, it should be understood that themicropellets can be adhered to any expanded collet-type snack foodproduct as described herein, before final dehydration or cooking stepsincluding baking or frying.

Micropellets within Baked Dough Products

In a final embodiment, micropellets as described herein are also usefulin snack food embodiments comprising sheetable or sheeted doughs;namely, the micropellets may be embedded within doughs during sheetingsteps and prior to cutting and baking steps. Thus, a plurality ofdiscrete micropellets can be combined together with a starch-comprisingcomponent in the form of a starch-based dough to form amicropellet-containing formulation. Thereafter, themicropellet-containing formulation may be subjected to a cooking stepsuch as baking or frying. Preferably, micropellets are distributed ontothe dough and lightly embedded within the dough during or following asheeting process. The dough comprising micropellets can subsequently beheated to cause expansion of the micropellets within the dough.Subsequent baking or drying with heat should ensure expansion into thedough. Thus, the micropellets may be used in baked products and/or bakedprocessing lines for the production of a number of snack foods includingwithout limitation pretzels, crackers, cookies, and bagel chips. By wayof illustration, micropellets may be used in Reading Bakery Systems(RBS). RBS provide platforms for a number of different products. Ingeneral, RBS comprise the steps of mixing and dough forming, followed bybaking and drying. Dried products may then be packaged and distributedor sold to consumers.

Dough formulations may be mixed by batch or continuous processes such asthrough a continuous mixer. The dough is then transported for formationor shaping, which may include without limitation sheeting or lowpressure extrusion. Shaping may be performed using a roll sheeter suchas a 2- or 4-roll sheeter. Micropellets may be added onto doughs duringsheeting steps, wherein the micropellets are combined with the doughjust prior to passing through the last set of rollers to insert themicropellets into the dough. Briefly, when using a 2-roll sheeter, doughis transferred into a hopper mounted over rolls that rotate toward oneanother, which draw the rolls through them to form a single sheet. Whenusing a 4-roll sheeter, micropellet-containing dough formulations may befed into a sheeting system comprising upper and lowers sets of rolls.Moisture content of the micropellet-containing dough formulationscomprises a level of about 16.5% to ensure expansion of the micropelletsin the dough. The thickness of the sheet for a dough containingmicropellets may range from about 2 mm to about 3 mm. A rotary cuttingstation may then cut and shape the product, followed by seasoning andbaking steps. Preferably, baking is a short process lasting about 10minutes and using temperatures of about 350° F. to allow

FIG. 11A depicts an expanded snack food with expandable micropelletscomprising sea vegetable protein, wherein the expanded micropellets arevisibly apparent within the snack food as darkened portions of the foodproduct. FIG. 11B depicts a snack food product made by imbeddingmicropellets within a dough starch matrix. To the left, the product isshown after having imbedded the micropellets into the dough. To theright, the product is shown after expansion in an oven. Similarly, FIG.11C depicts a snack food made by imbedding micropellets within a dough,both before expansion (on the left) and after expansion (on the right).

The invention will now be further elucidated with reference to thefollowing examples, which should be understood to be non-limitative. Itshould be appreciated by those of ordinary skill in the art that thetechniques disclosed in the examples that follow represent onesdiscovered by the inventors to function well in the practice of theinvention and thus, constitute exemplary modes. One of ordinary skill inthe art, when armed with this disclosure, should appreciate that manychanges can be made in the specific embodiments while still obtainingsimilar or like results without departing from the spirit and scope ofthe present invention.

Example 1 Milk Protein Micropellet Formation

Micropellets were prepared using milk protein isolate (MPI) protein forthe production of random collets. Micropellets were produced on a Pavanextrusion line consisting of a single screw extruder (G-55 Extruder) andthe forming extruder (F55), as discussed above. The material was cookedand then fed into the forming extrusion line to form the dough. A diecomprising multiple orifices with a diameter of about 0.8 mm was usedtogether with the high speed cutter to obtain the desired product shape.Cut micropellets were collected via a hopper and dried overnight in aforced air convection oven.

The micropellets were produced using three different protein levels ofprotein to starch ratios: 60:40; 70:30; and 80:20. Different starcheswere also tested with the MPI. First, MPI was run together with aresistant starch, under the brand name ActiStar manufactured byCargill). However, this combination led to very poor expansion of themicropellets and therefore, further starches were run. In a second run,MPI was agglomerated together with a native corn starch at levels ofabout 60:40, about 70:30 and about 80:20. An acceptable amount ofexpansion was achieved.

Additional formulations of MPI were run using (1) a native potato starch(manufactured by Fecola), (2) a waxy starch (manufactured by Roquette),and (3) phosphorylated starch (modified corn starch manufactured byPaselli). Following formation of the micropellets, the expansion of themicropellets was evaluated. The waxy starch showed the best expansionupon frying, followed by the phosphorylated starch and then the nativecorn starch. Test runs also showed that the levels of starch may play animportant role in expansion, with increased expansion demonstrated athigher levels of starch.

Example 2 Soy Protein Micropellet Formation

Micropellets of soy protein isolate (SPI) were also manufactured andtested for suitable expansion properties. SPI micropellets weremanufactured with extrusion methods using (1) native corn starch and (2)waxy corn starch at levels of about 60:40 and about 70:30. The moisturewithin the random extruder was measured to about 17.5% with an augerspeed of about 130 rpm and a rotor speed of about 650 rpm. Betterexpansion was seen with the SPI:waxy corn starch micropellets uponfrying. It was observed that higher levels of starch lead to moreexpansion upon frying.

Example 3 Whey Protein Micropellet Formation

Micropellets of whey protein isolate (WPI) together with native potatostarch were also manufactured and evaluated. However, the WPI mixtureswere not easily extruded for forming into the micropellets and thematerials had already caked in the pre-conditioning steps, forming verysticky doughs. To mitigate the stickiness, about 50% of the WPI wassubstituted with SPI in a protein to starch ratio of about 60:40 (withthe protein fraction composed of about 50% WPI and about 50% SPI. Thisreduced the stickiness and produced suitable micropellets, however theproduct rate was substantially slower due to the poor wetting propertiesof WPI. It is believed that instantized WPI may be a more suitableprotein for formation of micropellets with subsequent expansion.

Example 4 Calcium Micropellets into Random Collets

During several test runs, particles of calcium were agglomerated and runthrough the random extruder. The table below contains data for theparticle size of the calcium carbonate agglomerations used during thesetrial runs for inclusion of calcium into random collets.

TABLE 3 Particle Size of Calcium Carbonate Agglomeration Particle Size %retained/passed +16 mesh 0.0 +60 mesh 66.5 −200 mesh  1.5

These micropellet agglomerates were comprised a moisture content ofabout 0.37% by weight on a wet basis. The agglomerates comprised astarch-based nucleus; in particular, maltodextrin was used toagglomerate the particles at a moisture content of about 8% by weight.White agglomerates of calcium further comprised about 36.5% calcium.

During test runs, about 861 grams of the calcium carbonate agglomerationwas added to about 100 pounds of yellow corn meal. About two liters ofwater was added to the dry mix of calcium and corn meal, with anin-barrel moisture content of about 15.7%. The rotor position or gap wasset to about 1.94 mm, and the stator head temperature was recorded to beabout 145° C. The auger speed was initially set to about 142 rpm. Alltest runs with this agglomeration comprised a rotor speed of about501.50 rpm. Product rate was measured to be about 7.2 lb/minute. Acontrol formulation comprising the same yellow corn meal (moisturecontent of about 11.9%) and water was also run and compared againstseveral formulations. Trial runs were compared to the control run andadjustments were made as necessary to achieve the target bulkdensity—that of the control group comprising only corn meal—about 4.6lbs/cubic foot.

In the final run, the blend of agglomerated calcium was increased toabout 1000 grams, with an increase in water to the dry mix from 2.0liters to about 2.3 liters and an in-barrel moisture content of about16.24%. The rotor position remained at about 2.07 mm, with an augerspeed of about 144 rpm, resulting in a more acceptable product with abulk density of about 4.8 lb/cubic foot. Table 4 below contains acomparison of the resulting data from these runs.

TABLE 4 Random extrusion parameters of Calcium Carbonate MicropelletsTrial Run 1 2 3 4 5 Ca Agglomerate 861 861 861 861 1000 (g) Corn meal(lb) 100 100 100 100 100 Water to dry 2.0 2.0 2.0 2.3 2.3 mix (L)Calculated In- 15.7 15.7 15.7 18.00 16.24 Barrel Moisture (%) RotorPosition 1.94 2.02 2.07 2.02 2.07 (mm) Head Temp (C.) 148 146 146 135143 Auger Speed 142 143 143 143 144 (rpm) Motor Load (%) 50 48-49 49 4545 Auger Amps 11.8 11.5 11.5 11.0 11.0 Rotor Amps 38.8 38.6 38.8 37.9-3838.7-39.1 Bulk Density 4.00 4.20 4.4 6.4 4.8 (lb/cf)

All but one sample achieved surprisingly good products, given theintroduction of flours that otherwise negatively impact the product andthe random extrusion equipment. However, to achieve the desired bulkdensity, some adjustments were made to test the process parameters. Intrial run number 2, an increase in rotor gap to about 2.02 mm withsimultaneous increase in auger speed to about 143 rpm increased the bulkdensity from about 4.00 lb/cubic foot to about 4.20 lb/cubic foot. Asubsequent increase in rotor gap to about 2.07 mm, in trial run number3, further increased the bulk density to a more desirable 4.4 lb/cubicfoot. Next, an increase in moisture content within the barrel to about18% was tested, resulting in a degraded, less desirable product with amuch higher bulk density of about 6.4 lb/cubic foot. Thus demonstratingthe negative effect of a higher moisture content in the extruder.Without being bounded by theory, it is believe that the higher moisturecontent together with the sugar content degrades the product withtempering time.

Example 5 Calcium Micropellets within Collet Matrix

With the same agglomerated calcium used in Example 4, about 861 poundsof agglomerate was combined with about 100 pounds of yellow corn meal(with a moisture content of about 12.0%). About 2.2 liters of water wasadded, with an in-barrel moisture content of about 16.19. The rotor gapwas set to between about 1.856 mm and 1.940 mm in several trial runs.Head temperature was measured to be between about 143 to about 144C,with auger speed at about 140 rpm. The same rotor speed of 501.50 rpmwas used, resulting in acceptable collets having a bulk density of about4.5 pounds/cubic foot.

Example 6 Testing Protein Micropellets within a Random Extruder

To test the principle that the random extruder can handle conveyance ofmicropellets of protein as compared to the protein in loose, powderform, several formulations comprising proteins were tested in the randomextruder. Formulation 1 was a control formula comprising 100% corn meal,as typically used in prior art. Formulation 2 comprised about 62.5% cornmeal and about 27.5% powdered protein (BioPro) in loose, unagglomeratedstate. Formulation 3 comprised about 85% corn meal and about 15%micropellets comprised of Porphyra, which contains proteins, vitaminsand minerals.

As expected, formulation 2 resulted in the blockage of the extruder. Onthe other hand, the extruder was able to handle the inclusion of thePorphyra micropellets very well, though the resulting expanded extrudatewas larger in size than the control. In addition, some of themicropellets did not melt. This was believed to be at least in part dueto the shear zone of the stator (with a gap of about 0.084 inches or0.21 mm), and a low moisture content, in which there was not enough of aplasticizing effect as to cause it to melt and expand as it was exposedto the drop in pressure. However, this proved to show that micropelletsor solid agglomerates can be handled by the random extruder.

Example 7 Random Extrusion of Formulations with Micropellet Mixtures

A formulation comprising about 59% corn meal and about 41% micropelletswas extruded in a random extruder. More specifically, the micropelletswere comprised of about 25% rice micropellets, 5% porphyra micropellets,1% tapioca micropellets, and 10% combu micropellets. In a first trialrun of this formulation, the resulting collets were long strips, whichare characteristic of low moisture. In a second run, the moisturecontent of the corn meal and micropellets was increased to about 16.5%,which is more characteristic of a level used for corn meal alone.Acceptable collets were formed, while noting that the rice micropelletsand tapioca micropellets melted better. However, the remainingmicropellets in the mix remained intact, possibly due to the smallersize of these micropellets and/or the moisture level.

Example 8 High Protein Formulations in the Random Extruder

A 50-lb batch of formulation was mixed to product random collets with 5grams of protein per one ounce serving. Micropellets comprising SPI witha waxy corn starch were combined with corn grits in the followingamounts: about 10.20 pounds of micropellets and about 39.8 pounds ofcorn meal. The corn meal was mixed with the protein micropellets and themixture was hydrated to a moisture content of about 16%. Afterhydration, it was noted that the micropellets and corn grits were of asimilar particle size. The hydrated mixture was metered into a randomextruder using a gravimetric feeder. Processing parameters were adjustedto provide for better expansion, as processing under the traditionalcorn meal processing conditions yielded very poorly expanded products.Namely, feeder rpm was slowed down to about 130 rpm, and the quillposition was increased to about 0.008 inch. Resulting collets showed nomicropellet residue, indicating that the micropellets totally meltedinto the collet matrix. Flavor of the mixture of SPI and waxy starch wasnot perceived in the dried base.

Example 9 High Protein Formulations in the Random Extruder

A 50-lb batch of formulation was mixed to produce random collets with 5grams of protein per one ounce serving. Micropellets comprised of MPIand waxy corn starch were manufactured and pre-hydrated to a moisturecontent of about 17% by weight. The ratio of micropellet to corn mealwas: MPI/waxy corn starch micropellets (70:30) at about 19.8% and cornmeal at about 80.22%.

The micropellet-starch mixture was run through a random extrudercomprising a stainless steel stator and the conveyor screw was modifiedto reduce the residence time of the material conveyed in the work zone.Processing parameters of the run is set forth below.

TABLE 5 Random Extruder parameters using Stainless Steel StatorProcessing parameter Corn Meal 5 g/oz Formula 10 g/oz Formula Quillposition 0.0067 in 0.0067 in. 0.0082-0.0073 in Auger rpm 137 137 137Temperature (F.) 276 276 267 Auger Load 0.50 0.50 0.50

Both formulas ran well using the stainless steel plate, with no visiblemicropellet residue in the collet matrices and no evidence of fouling onthe extruder. The products ran completely from start to finish for over15 minutes, which was an improvement over the bronze plate. The 5 g/ozFormula had a texture and appearance very similar to that of the cornmeal control base formula, with a slightly white color. Milky flavorfrom the MPI was almost undetected, and there was good mouth fill withno tooth packing. However, the 10 g/oz formula had an undesirablemouthfeel, a lot of toothpacking, and a cooked dairy note.

Example 10 Whole-Grain Cornmeal Formulations in the Random Extruder

Micropellets comprising of 100% whole-grain corn were manufactured usingonly (100%) ground corn kernel to manufacture the whole-grain cornmicropellets. Thus, the micropellets may consist solely of whole grainseeds.

A 200 lb batch formulation was mixed to produce random collets with8-grams of whole-grain per one ounce serving. The formulation comprised34% whole-grain corn micropellets (9.5% moisture content) and 66%degermed cornmeal (12.4% moisture content). No direct pre-hydration wasperformed to the whole-grain corn micropellets. Instead, all necessarywater to achieve formulation target of 16.5% moisture content was addedonly to the degermed cornmeal. After this exclusive pre-hydration of thedegermed cornmeal was accomplished, whole-grain corn micropellets andexclusively prehydrated degermed cornmeal were blended and allowed toequilibrate for 4 hours. In addition, a control formula was prepared byblending 200 lb of degemed cornmeal and 9.9 lb of water for 15-20 minand allowed to equilibrate for 30 min. The 8-gram whole-grain/ozformulation and control formulation as described above were run throughthe random extruder with a standard bronze rotary die plate and no otherspecial modifications. Processing parameters of the run is set forthbelow.

TABLE 6 Random Extruder parameters with whole- grain corn micropelletsformulation. Degermed Corn Meal 8-g whole-grain/oz Processing parameter(Control Formula) Formula Quill position 0.0063 in 0.0069 in. Auger rpm142 142 Stator Head 288 284 Temperature (F.) Bulk Density (lb/cu-ft)4.55 4.52

The control and 8-g whole-grain/oz formulas ran well using standardbronze plate and operating conditions, with no visible micropelletresidue in the collet matrices and no evidence of fouling on theextruder. The products ran completely from start to finish for over 30minutes. Moreover, the extrusion process was able to start-up with the8-g whole-grain/oz Formula, which is not often possible when attemptingto process whole-grain cornmeal. The 8-g whole-grain/oz Formula had bulkdensity, texture, appearance, and flavor, very similar to that ofdegermed cornmeal control formula, with a slightly less yellow color.

Micropellets made by way of extrusion, according to Example 10, andconsisting of modified starch and whey protein isolate were analyzedusing three analytical techniques for testing starch gelatinization,pasting profile, and degree of macromolecular degradation—1)differential scanning calorimetry (DSC), 2) rapid visco analysis (RVA),and 3) phase transition analysis (PTA). Results, further discussedbelow, indicated that the extruded micropellets completely gelatinizeand exhibit an RVA peak viscosity of 63.5 cP, PTA flow of 112.7, andsoftening temperatures of about 53.0° C. Pellets made by way ofmarumerization (MRM) were also tested to compare with the extrudedmicropellets (EXT).

Sample Preparation

A falling number mill was used to grind the samples in a two-passprocess, followed by sieving to obtain particle size below 500 μm. Themoisture content of the ground sample was measured using AACC air ovenmethod 44-19 in a Model 160DM Thelco Lab Oven (Precision Scientific,Chicago, Ill.) at 135° C. for 2 hours. The original moisture content ofthe samples was 10.1% (EXT1) and 10.5% (MRM). All moisture contents areexpressed on wet basis.

Differential Scanning Calorimetry (DSC)

Approximately 10 mg of samples were hydrated to 66% moisture, sealed insteel pans and equilibrated overnight in a refrigerator. A standardgelatinization test was conducted by heating the pans in the DSC (Q100,TA Instruments, New Castle, Del.) from 10° to 140° C. at a heating rateof 10° C./min. Gelatinization temperature range (onset, peak and end)and enthalpy were determined for each sample. All tests were carried outin duplicate.

FIG. 12A depicts the DSC scan for the extruded micropellets (EXT). FIG.12B depicts the DSC scan for micropellets made by way of marumerization(MRM). The corresponding data for the residual gelatinization propertiesof the MRM sample can be found below in Table 7.

TABLE 7 Residual gelatinization properties of MRM micropellets MRM rep1MRM rep2 Avg Std Dev Start temp (° C.) 68.35 67.72 68.04 0.45 Peak temp(° C.) 76.04 75.71 75.88 0.23 End temp (° C.) 88.12 85.82 86.97 1.63Enthalpy (J/g) 4.176 4.584 4.38 0.29

Both replicates of the DSC scans revealed that the EXT sample did notexhibit any peak, which indicates that the starch was completelygelatinized. On the other hand, the MRM sample had a residualgelatinization peak, which indicates that a substantial portion of thestarch in the product was still ungelatinized. Specifically, Table 7indicates a peak gelatinization temperature of 75.88±0.23 that is fairlytypical for many starches. The typical gelatinization enthalpy of nativestarches range from 5-20 J/g. The MRM sample had a residual enthalpy ofgelatinization of 4.38±0.29 J/g, confirming that a substantial amount ofthe starch was ungelatinized.

Rapid Visco Analysis (RVA)

Pasting properties of the EXT and MRM samples were also determined usinga rapid visco analyser (RVA4, Newport Scientific Pty. Ltd., Australia).For RVA analysis, sample moisture was first adjusted to 14% by addingdistilled water. Specifically, 3 grams of sample was added to 25 ml ofwater in an aluminum test canister. The RVA was preheated to 50° C. for30 minutes prior to testing. A 13 min standard RVA temperature profilewas used: 1 min holding at 50° C., 3 minutes 42 second temperature rampup to 95° C., 2 minutes 30 seconds holding at 95° C., 3 minutes 48second temperature ramp down to 50° C., and 2 minutes holding at 50° C.Pasting properties, such as peak, trough and final viscosities, weredetermined. All tests were carried out in duplicate.

The results of the RVA are summarized below in Table 8. The RVA pastingcurves for the sample runs of the EXT samples are shown in FIGS. 13A and13B. The EXT sample did not exhibit much increase in viscosity as thetesting proceeded. As shown in Table 8, the EXT sample comprised anaverage peak viscosity of about 63.5 cP. This indicates that the starchfraction was degraded during the processing and had lost all or most ofits swelling capacity. On the other hand, as depicted in FIGS. 14A and14B, the MRM sample had a substantially higher peak viscosity. Table 8shows the average peak viscosity for the MRM sample runs to be about1761.5 cP, which indicates that their processing conditions were lesssevere and the starch fraction retained its swelling capacity.

TABLE 8 Pasting (RVA) parameters for (a) EXT and (b) MRM samples. Break-Peak Pasting Peak Trough down Final Setback time Temp (cP) (cP) (cP)(cP) (cP) (min) (° C.) (a) EXT1 79.0 15.0 64.0 46.0 31.0 6.9 57.4 rep1EXT1 48.0 1.0 47.0 62.0 61.0 1.7 95.0 rep2 Average 63.5 8.0 55.5 54.046.0 4.3 76.2 Std Dev 21.9 9.9 12.0 11.3 21.2 3.7 26.6 (b) MRM 1682.01340.0 342.0 1650.0 310.0 4.6 75.9 rep1 MRM 1841.0 1424.0 417.0 1789.0365.0 4.7 50.2 rep2 Average 1761.5 1382.0 379.5 1719.5 337.5 4.6 63.0Std Dev 112.4 59.4 53.0 98.3 38.9 0.0 18.2Phase Transition Analyzer (PTA)

PTA is a relatively new method for determining the softening temperature(Ts) and flow temperature (Tf) of a bio polymeric material. These areflow-based measurements and are similar to glass transition (Tg) andmelting (Tm) temperatures, although the latter are thermal events. ThePTA characterizes softening and flow transitions of complex recipes byusing a combination of time, temperature, pressure and moisture. Itconsists of two sealed chambers separated by an interchangeablecapillary die. The chambers house electric heaters and contain a hollowcavity for cooling fluid. The pistons are mounted together throughsidebars. Air cylinders are mounted at the bottom and maintained atconstant pressure. A linear-displacement transducer measures thesample's deformation, compaction and flow relative to initial sampleheight, as the sample temperature is raised at a set rate underpressurized conditions.

For phase transition analysis of the EXT and MRM samples, samples wereequilibrated overnight in a relative humidity chamber at 99% RH foradjustment of moisture. The final moistures prior to testing were 12.5and 13%, respectively, for EXT and MRM. Approximately 2 g sample wasintroduced into the test chamber of the Phase Transition Analyzer(Wenger Manufacturing Inc., Sabetha, Kans.), and subject to initialcompaction at 100 kPa with a blank die (no opening) underneath.Temperature was then ramped up at 8° C. per min with a startingtemperature of 1° C., while maintaining the chamber pressure at 80 kPa.Ts was obtained as the midpoint of the temperature range over which thesample exhibited softening (displacement over a set threshold of 0.0106mm/° C. as measured by a transducer). The blank die was then replaced bya 2 mm capillary die and heating was continued. T_(f) was obtained asthe temperature at which the sample started to flow through thecapillary.

The results of the PTA scans are shown in FIGS. 15A and 15B (EXT runs)and FIGS. 16A and 16B (MRM runs), with corresponding data summarizedbelow in Table 9.

TABLE 9 PTA data T_(s)(° C.) Std T_(f)(° C.) Std Rep1 Rep2 Avg Dev Rep1Rep2 Avg Dev EXT1 54.2 51.9 53.0 1.6 114.2 111.2 112.7 2.1 MRM 55.8 58.657.2 2.0 163.5 157.9 160.7 4.0

The above PTA data supports the inference made from analysis of RVAresults. The EXT sample had lower Ts than the MRM sample (53.0±1.6° C.versus 57.2±° C.). The former also had a substantially lower Tf(112.7±2.1° C. versus 160.7±4.0° C.). This indicates that the EXTmicropellets had a higher macromolecular degradation than the MRM.

The above examples help to illustrate several advantages of the methodand formulations described herein. First, because the micropellets inone embodiment are created using methods with low shear, degradation ofheat labile nutrients is substantially eliminated. Second, themicropellets may be used to encapsulate flavors for inclusion withinsnack foods. In particular, flavors that are typically highly volatilemay be introduced to maintain the taste sensation provided by theflavors even after long storage times. In addition, aromas that areotherwise volatile can be likewise maintained. Third, the micropelletscan be used to entrap and maintain color such that natural vegetable andfruit powders can be used to add color to snack foods. Fourth, infinitecombinations of base agglomerates made with starches such as rice,tapioca, potato, corn and any combination thereof with other ingredientsthat may add other nutritional value to snack foods are possible, whilemaintaining the texture of the foods. For the random collet, this isespecially advantageous given the ability to add and use differentnutritional components to an already unique snack food, making therandom collet unique in many aspects. Addition of highly desirablenutritional components such as protein will increase the demand andpopularity of the random collet, which is already desirable for itscrunchy texture. Sixth, the micropellets provide a more uniform particlesize for random extrusion processes; thus, reducing the issue ofconveyance to vary the ingredients of the random collet.

The use of any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention. Unless otherwise defined, all technical and scientificterms and abbreviations used herein have the same meaning as commonlyunderstood by one of ordinary skill in the art to which the inventionpertains.

The method illustratively disclosed herein suitably may be practiced inthe absence of any element which is not specifically disclosed herein.In some embodiments, the methods described herein may suitably comprise,consist of, or consist essentially of, the steps disclosed. Similarly,the formulations may comprise, consist of, or consist essentially of thecomponents disclosed. Individual numerical values and/or ranges arestated as approximations as though the values were preceded by the word“about” or “approximately.” As used herein, the terms “about” and“approximately” when referring to a numerical value shall have theirplain and ordinary meanings to a person of ordinary skill in the art towhich the disclosed subject matter is most closely related.

While this invention has been particularly shown and described withreference to preferred embodiments, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.The inventors expect skilled artisans to employ such variations asappropriate, and the inventors intend the invention to be practicedotherwise than as specifically described herein. Accordingly, allmodifications and equivalents of the subject matter recited in theclaims appended hereto are included within the scope of the claims aspermitted by applicable law. Moreover, any combination of theabove-described elements in all possible variations thereof isencompassed unless otherwise indicated herein or otherwise clearlycontradicted by context.

What is claimed is:
 1. An food-grade micropellet comprising: a. anexpandable starch comprising component; and b. a plurality of fineparticles agglomerated together with said expandable component, whereinsaid plurality of fine particles is derived from a non-starch source,and wherein said fine particles comprise a particle size of less thanabout 300 microns; wherein said micropellet is a unexpanded solid pelletagglomerate comprising a spherical or cylindrical shape with a diameterof between about 500 to about 700 μm, said; food-grade micropelletincorporated in for the preparation of ready-to-eat snack foods.
 2. Themicropellet of claim 1 wherein said expandable component is selectedfrom the group consisting of corn, potato, rice and tapioca.
 3. Themicropellet of claim 1 wherein said expandable component comprises cornmeal.
 4. The micropellet of claim 1 wherein said micropellet iscomprised of at least 60% of said plurality of fine particles.
 5. Themicropellet of claim 1 wherein said fine particles comprise a protein.6. The micropellet of claim 1 wherein said fine particles comprise amineral.
 7. The micropellet of claim 6 wherein said micropelletcomprises between about 35% to about 37% calcium.
 8. The micropellet ofclaim 1 further comprising up to about 10% microcrystalline cellulose.9. The micropellet of claim 1 comprising a bulk density of between about500 to about 700 g/L.
 10. The micropellet of claim 1 wherein saidplurality of fine particles is derived from dairy and is selected fromthe group consisting of a milk protein isolate, a soy protein isolateand a whey protein isolate.
 11. The micropellet of claim 1 wherein saidmicropellet comprises a fine particle to starch-comprising component ofbetween about 1.5 to about
 4. 12. The micropellet of claim 1 whereinsaid expandable starch comprising component comprises a waxy cornstarch.
 13. The micropellet of claim 1 wherein said expandable starchcomprising component comprises a modified potato starch.
 14. Themicropellet of claim 1 comprising a moisture content of about 8-10%. 15.The micropellet of claim 1 comprising a phase transition analysissoftening temperature of between about 51.9° C. to about 54.2° C. 16.The micropellet of claim 1 comprising a phase transition analysis flowtemperature of between about 111.2° C. to about 114.2° C.